Field device controlling system

ABSTRACT

One or more field devices, and a controller are connected so as to be able to communicate with a field device through a first communication route, and a device monitoring unit that is connected so as to be able to communicate with the field device through a second communication route are provided, wherein the device monitoring unit is provided with a checking tool for checking a status of the field device and the status of communication through the first and/or the second communication routes, based on a response received through the second communication route from the field device in response to a signal sent through either the first communication route or the second communication route.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. §119 to JapanesePatent Application No. 2011-073252, filed Mar. 29, 2011, which isincorporated herein by reference.

FIELD OF TECHNOLOGY

One aspect of the present invention relates to a field devicecontrolling system.

BACKGROUND

The technologies set forth in Japanese Unexamined Patent ApplicationPublication H9-244732; Japanese Unexamined Patent ApplicationPublication 2010-141654; Japanese Unexamined Patent ApplicationPublication H07-209050; and Japanese Unexamined Patent ApplicationPublication H10-047302 are known as examples of technology formonitoring or controlling the status of field devices. Moreover, thetechnology set forth in Japanese Unexamined Patent ApplicationPublication H11-212901 is known as an example of a technology forrecognizing correctly whether or not an electronic device is connected.

However, in the conventional technology no thought is given toincluding, in the scope of monitoring, the communication routes thatform the controlling systems or monitoring systems for the field deviceswhen monitoring the status of the field devices.

One object of the present invention is to be able to check the status ofcommunication through the communication routes that form the controllingsystems or monitoring systems for the field devices when monitoring thestatus of the field devices.

Note that there is no limitation to the aforementioned object, butrather being able to obtain effects in operation that are not providedby the conventional technology, which are effects in operation derivedthrough the various structures illustrated in the form for carrying outthe present invention, described below, can also be positioned as otherobjects of the present invention.

SUMMARY

One example of the present invention is a field device controllingsystem having one or more field devices; a controller that is connectedso as to be able to communicate through a first communication route to afield device; and a device monitoring unit that is connected so as to beable to communicate through a second communication route to the fielddevice. The device monitoring unit can include a checking tool forchecking a status of a field device and a status of communicationthrough the first and/or the second communication route.

Here the checking tool may have a checking tool for executing, throughthe second communication route, a check regarding a connection status,device information, or an analog input of a field device, and forexecuting, through the second communication route, a check regarding ananalog output of the field device, controlled by the controller throughthe first communication route.

Moreover, the checking tool may control the statuses of progress of eachindividual check, for the respective checks, separately for each fielddevice.

Furthermore, the first communication route may include an analogcommunication route for transmitting analog signals between fielddevices; and the second communication route may include a digitalcommunication route for sending digital signals superimposed, asfrequency signals, on the analog signals in the analog communicationroute.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating an example of a process controllingsystem according to an example.

FIG. 2 is a block diagram illustrating an example of a configuration fora field device and an I/O unit, compatible with the smart communicationillustrated in FIG. 1.

FIG. 3 is a block diagram illustrating an example of a configuration ofthe device monitoring unit illustrated in FIG. 1.

FIG. 4 is a functional block diagram of a device monitoring unitillustrated in FIG. 1 and FIG. 3.

FIG. 5 is a flowchart for explaining the loop check (at startup) by thedevice monitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 6 is a flowchart for explaining the loop check (during operations)by the device monitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 7 is a diagram illustrating one example of a Loop Checking Toolwindow (Device List tab) displayed on a monitor of the device monitoringunit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 8 is a diagram illustrating an example of a display in a SearchParameter Setup window displayed on the monitor of the device monitoringunit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 9 is a flowchart for explaining the device existence checkingprocess by the device monitoring unit illustrated in FIG. 1, FIG. 3, andFIG. 4.

FIG. 10 is a diagram illustrating one example of a Loop Checking Toolwindow (Commissioning tab) displayed on a monitor of the devicemonitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 11 is a flowchart for explaining the commissioning process by thedevice monitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 12 is a diagram illustrating one example of a Loop Checking Toolwindow (Output Value Check screen) displayed on a monitor of the devicemonitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 13 is a diagram illustrating one example of a Loop Checking Toolwindow (Analog Input Check tab) displayed on a monitor of the devicemonitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 14 is a flowchart for explaining the analog input checking processby the device monitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 15 is a diagram illustrating one example of a Loop Checking Toolwindow (Analog Output Check tab) displayed on a monitor of the devicemonitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 16 is a flowchart for explaining the analog output checking processby the device monitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

FIG. 17 is a diagram illustrating one example of a Loop Checking Toolwindow (Progress Check tab) displayed on a monitor of the devicemonitoring unit illustrated in FIG. 1, FIG. 3, and FIG. 4.

DETAILED DESCRIPTION

An example of the present invention is explained below in reference tothe drawings. However, the example explained below is no more than anillustration, and is not intended to exclude various modifications andapplications to technologies not explicated below. That is, the presentinvention can be embodied in a variety of modified forms (such ascombinations of individual examples), in the scope that does not deviatefrom the spirit and intent thereof. In the descriptions of the drawingsbelow, identical or similar components are assigned identical or similarcodes. The drawings are schematic, and do not necessarily match actualdimensions, ratios, or the like. Furthermore, even within these drawingsthere may be portions having differing dimensional relationships andproportions.

(1-1) System Configuration

FIG. 1 is a diagram illustrating an example of a process controllingsystem according to an example. The process controlling system 1,illustrated in FIG. 1, is provided, by means of illustration, with oneor more smart communication-compatible field devices (hereinafter termedalso “smart communication-compatible devices”) 10 and one or more fielddevices 12 which, although not compatible with smart communications, arecompatible with other types of communications.

One example of “smart communications” is communication based on the HART(Highway Addressable Remote Transducer) communication protocol or fieldbus communication based on a field bus communication protocol. Oneexample of “other types of communications” is communication based on aproprietary standard, such as Xbus, or the like, described below. TheHART® communication, the field bus communication, and the communicationof the proprietary standard are all examples of digital communication.

A transmitter and a positioner are examples of field devices 10 or 12.Examples of transmitters are various types of sensors such as flow ratesensors, pressure sensors, temperature sensors, and the like. Examplesof positioners are devices that perform conversion of electric signalsinto signals in accordance with, for example, air pressures that are tobe controlled, and then perform positional control of valves, such asflow rate controlling valves or pressure controlling valves, or thelike, in accordance with those signals.

Moreover, the process controlling system 1 may be provided with one ormore smart communication-compatible input/output (I/O) units 11, one ormore input/output (I/O) units 13 that are not compatible with smartcommunications, a device monitoring unit 15, a link module 15A, acontroller 17, and an operating unit 19, and the like.

In short, the operating unit 19 is able to communicate with thecontroller 17, and with each of the field devices 10 and 12 through theI/O units 11 and 13. Through this communication, the operating unit 19is able to obtain measured values from the field devices 10 and 12,apply setting values and control values to the field devices 10 and 12based on the measured values, and the like. In other words, thecontroller 17 and the operating unit 19 form one example of acontrolling system that performs process control through a first controlcircuit through the I/O units 11 and 13.

In contrast, the device monitoring unit 15 is able to communicate withthe smart communication-compatible field devices 10 through the smartcommunication-compatible I/O units 11 in cooperation with the linkmodule 15A. Through this communication, the device monitoring unit 15 isable to obtain information indicating the statuses of, for example, thefield devices 10 (for example, process information, fault information,and the like). In other words, the device monitoring unit 15 and thelink module 15A form an example of a monitoring system for monitoringthe statuses, etc., of the smart communication-compatible devices 10through a second communication route through the I/O units 11.

More specifically, the smart communication-compatible I/O units 11, thedevice monitoring unit 15, the link module 15A, the controller 17, andthe operating unit 19 are able to connect to a specific communicationroute 16. An example of a communication route 16 is a TCP/UDPcommunication route wherein digital communication is possible based onthe TCP (Transmission Control Protocol) and UDP (User DatagramProtocol).

An Ethernet (registered trademark) communication route (a cable) is anexample of a TCP/UDP communication route (digital communication route)16. Consequently, the operating unit 19 is able to perform TCP/UDPcommunication with, for example, the device monitoring unit 15 and thecontroller 17, and the like, and the device monitoring unit 15 is ableto perform TCP/UDP communication with, for example, the link module 15Aand the I/O units 11, and the like.

The controller 17, by way of illustration, can be connected through aspecific communication route 18 so as to be able to communicate mutuallywith the I/O units 11 and 13. An example of the communication route 18is a proprietary standard, Xbus, that is specialized to communicationfunctions for the controller 17 and the I/O units 13. Xbus is an exampleof a digital communication route that enables digital communicationbetween the controller 17 and the I/O units 13.

The smart communication-compatible devices 10 can be connected to thesmart communication-compatible I/O units 11. Field devices 12 can beconnected to the I/O units 13. These connections can use analogcommunication routes that transmit analog DC signals (for example,between 4 mA and 20 mA).

The analog DC signals are an example of signals that express variablesin accordance with the field devices 10 and field devices 12. Examplesof the variables include flow rates, pressures, temperatures, and othermeasured values, along with control values such as the degrees ofopening, for example, of pumps and valves, obtained from field devices10 such as flow rate gauges, pressure gauges, temperature gauges, andthe like.

Consequently, the field devices (hereinafter also called just “devices”)10 and 12 are able to send analog DC signals of electric current values(between 4 and 20 mA), in accordance with measured values, to thecontroller 17 through the I/O units (hereinafter also called “I/Omodules”) 11 and 13, and are also able to receive analog DC signals ofelectric current values (between 4 and 20 mA) in accordance with settingvalues or control values, or the like, that are sent from the controller17 through the I/O units 11 and 13.

Here the smart communication-compatible I/O units 11 and field devices10 are able to transmit to each other signals wherein digital signalsare superimposed onto the analog DC signals. In other words, the I/Ounits 11 and field devices 10 are able to perform simultaneously analogcommunication using the analog DC signals (between 4 and 20 mA) anddigital communication using digital signals.

The digital signals that are superimposed onto the analog DC signalsare, by way of illustration, signals that express various types of datathat can be obtained by the smart communication-compatible device 10.Examples of the various types of data include information indicating thestatuses of the smart communication-compatible devices 10 (for example,process information or information indicating the status of a device10). Note that measured values and control values, and the like, for thesmart communication-compatible devices 10 may be included in thesevarious types of data.

An example of a smart communication protocol wherein a digital signal issuperimposed onto an analog DC signal is the HART® communicationprotocol that has been mentioned already. In the HART® communicationprotocol, a digital signal that has been converted (for example, phasemodulated) so as to express digital values of 0 and 1 using twodifferent frequency signals (for example, 1200 Hz and 2200 Hz) issuperimposed onto an analog DC signal of between 4 and 20 mA.

When an I/O unit 11 (or field device 10) receives, from a field device10 (or an I/O unit 11) an analog DC signal onto which a digital signalhas been superimposed in this way, it divides the received signal intoan analog DC signal and a digital signal. Doing so makes it possible forthe I/O unit 11 (or field device 10) to obtain values or data thatindicate the respective signals that have been separated.

In other words, the analog communication route between the field devices10 and 12 and the I/O units 11 and 13, and the digital communicationroute 18 between the I/O units 11 and 13 and the controller 17, form oneexample of a first communication route in a controlling system.

On the other hand, the analog communication route between the smartcommunication-compatible field devices 10 and I/O units 11 and thedigital communication route 16 between the smartcommunication-compatible I/O units 11 and the link module 15A and thedevice monitoring unit 15 form one example of a second communicationroute in a monitoring system.

Examples of configurations of the smart communication (HART®communication)-compatible I/O units 11 and field devices 10, describedabove, are each illustrated in FIG. 2.

(1-1-1) Smart Communication-Compatible I/O Unit

The I/O unit 11 illustrated in FIG. 2, by way of illustration, has aninterface (IF) 110 that provides a connection to an Xbus 18; acalculating portion 111; an analog-digital converting device (ADC) 112;a digital-analog converting device (DAC) 113; a memory 114; and a smartcommunications processing portion 115. The smart communicationsprocessing portion 115 may be provided in a plurality thereof, so as tobe able to handle a plurality of devices. The smart communicationsprocessing portion 115, by way of illustration, comprises: a networkinterface card (NIC) 1151 for providing a connection with the TCP/UDPcommunication route 16; a calculating portion 1152; a memory 1153; asmart communication (HART® communication) modem 1154; aseparating/superimposing portion 1155; and an interface 1156.

Schematically, the communication between the controller 17 and a fielddevice 10 through an I/O unit 11 is performed through a route thatpasses through the interface 110, the calculating portion 111, the ADC112 or the DAC 113, the separating/superimposing portion 1155, and theinterface 1156.

Note that the calculating portion 111 stores, into the memory 114,digital signals that are inputted from the ADC 112 and digital signalsthat are applied to the DAC 113. In other words, information such ascontrol values that are applied to the field device 10, and measuredvalues, and the like, that are obtained from the field device 10, arestored in the memory 114.

The communication between the device monitoring unit 15 (or the linkmodule 15A) and the field device 10, through an I/O unit 11, for theaforementioned communication between the controller 17 (the operatingunit 19) and the field device 10, is performed in a route that passesthrough the NIC 1151, the calculating portion 1152, the smartcommunications modem 1154, the separating/superimposing portion 1155,and the interface 1156.

For example, control information, such as commands, or the like, whichare digital signals that are asserted by the device monitoring unit 15(or the link module 15A) are inputted into the smart communicationsmodem 1154 through the NIC 1151 and the calculating portion 1152, and,in the modem 1154, are converted into two different frequency signalscorresponding to digital values (through, for example, FSK (FrequencyShift Keying) modulation), and then are superimposed onto the analog DCsignal to the field device 10 by the separating/superimposing portion1155. This produces a smart communication signal wherein a digitalsignal is superimposed, as a frequency signal, on the analog DC signal,and the smart communication signal is outputted through the interface1156 to the applicable field device 10.

On the other hand, the smart communication signal received through theinterface 1156 is split by the splitting/superimposing portion 1155 intoan analog DC signal and the two different frequency signals that aresuperimposed on the analog DC signal. The analog DC signal is applied tothe calculating portion 111 after conversion into a digital signal bythe ADC 112, as described above. The two different frequency signalsindicate, for example, information obtained from the field device 10(device information, etc.), and are applied to the calculating portion1152 after conversion (for example, demodulation) into the respectivelycorresponding digital values by the smart communications modem 1154. Thecalculating portion 1152 sends the digital signals obtained from themodem 1154 to the device monitoring unit 15 (or the link module 15A)through the NIC 1151.

Note that the calculating portion 1152 is able to store, into the memory1153, the digital signal inputted from the NIC 1151 and/or the digitalsignal inputted from the smart communications modem 1154. In otherwords, the control information applied from the device monitoring unit15 (or the link module 15A), and the device information, and the like,obtained from the field devices 10 may be stored, as necessary, in thememory 1153.

Additionally, the calculating portion 1152 can connect to thecalculating portion 111 through an internal bus, not shown, so as to beable to communicate, making it possible to receive, from the calculatingportion 111, information stored in the memory 114. Similarly, thecalculating portion 111 is able to receive, from the calculating portion1152, information stored in the memory 1153.

The device information obtained from the field devices 10 (hereinafteralso termed “live list information”) may include, if necessary,information elements on the same level as device definition informationthat is stored and controlled by the device monitoring unit 15.

Examples of these information elements include the smart communicationprotocol revision, the node number of the link module 15A, networkaddress information for the link module 15A, network address informationfor the I/O modules 11, I/O module numbers, slot numbers, device tags,device IDs, device types, device revisions, vendors, vendor IDs, modulenames, and so forth.

Note that the calculating portions 111 and 1152 are examples of signalprocessors that are provided with calculation processing capabilities.CPUs (central processing units), MPUs (microprocessing units), DSPs(digital signal processors), ASICs (application-specific processors),and the like, may be used in the calculating portions 111 and 1152.

(1-1-2) Smart Communication-Compatible Devices

On the other hand, a smart communication-compatible device 10, asillustrated in FIG. 2, is provided with, for example, a calculatingportion 101, an ADC 102, a DAC 103, a memory 104, aseparating/superimposing portion 105, a sensor processing portion 106, asmart communications modem 107, and an interface (IF) 108 for providinga connection to an analog communication route though an I/O module 11.

Schematically, the analog communication between the smartcommunication-compatible device 10 and the I/O unit 11 is performedthrough a route through the calculating portion 101, the ADC 102 and theDAC 103, the separating/superimposing portion 105, and the interface 108(or in other words, a route that does not pass through the smartcommunications modem 107).

For example, a control value that is received through an analog DCsignal from the I/O unit 11 through the interface 108 is inputtedthrough the separating/superimposing portion 105 into the ADC 102, andinputted into the calculating portion 101 after being converted into adigital signal through ADC. The calculating portion 101 performs aprocess of a sensor processing portion 106 (for example, valve control,or the like) based on the control value of the digital signal. On theother hand, a measured value that is obtained from, for example, thesensor processing portion 106 by the calculating portion 101 isconverted by the DAC 103 into an analog DC signal, and then is inputtedinto an I/O unit 11 through the separating/superimposing portion 105 andthe interface 108.

Note that the calculating portion 101 stores, into the memory 104,digital signals that are inputted from the ADC 102 and digital signalsthat are applied to the DAC 103. In other words, information such ascontrol values applied from the controller 17 and measured valuesobtained from the sensor processing portion 106 can be stored in thememory 104.

In contrast to the analog communication described above, the digitalcommunication between the smart communication-compatible device 10 andan I/O unit 11 is performed through a route that passes through thecalculating portion 111, the smart communications modem 107, theseparating/superimposing portion 105, and the interface 108.

For example, the two different frequency signals that are superimposedon the analog DC signal that is received by the interface 108 (forexample, control information such as smart communication commands, orthe like) are separated by the separating/superimposing portion 105, areconverted, by the smart communications modem 107, into digital valuescorresponding to the frequency signals, and are inputted into thecalculating portion 101. This makes it possible for the calculatingportion 101 to generate a response, for example, to the devicemonitoring unit 15 (or the link module 15A) that is the source thatissued the command, in response to the control information that has beenreceived. This response may include, for example, device informationthat is stored in the memory 104.

On the other hand, the digital signal, generated by the calculatingportion 101, directed to the device monitoring unit 15 (or the linkmodule 15A) (for example, the aforementioned response) is converted bythe smart communications modem 107 into the two different frequencysignals in accordance with the digital values thereof, and thensuperimposed, by the separating/superimposing portion 105, onto theanalog DC signal to the I/O unit 11, and then inputted into the I/O unit11 through the interface 108.

Note that the calculating portion 101, as with the calculating portion111 and calculating portion 1152 in the I/O unit 11, is an example of asignal processor that is provided with calculation processingcapabilities, and may use a CPU or an MPU, a DSP, an ASIC or the like.

Next, in FIG. 1 and FIG. 2, the controller 17 controls the executionstatuses of the processes by controlling, for example, the field devices10 and/or field devices 12. To provide a non-limiting example, thecontroller 17 may adjust the degree of opening, or the like, of a valve,or the like, by controlling one of the field devices 10 (or 12) as apositioner of an actuator, or the like, based on a measured valueobtained from the field device 10 (or 12), as a transmitting device thatis a sensor, or the like.

The operating unit 19 is able to output, to a monitor, or the like, theoperating statuses, or the like, of the field devices 10 and 12 based onmeasured values of the field devices 10 and 12, receive from thecontroller 17. On the other hand, the operating unit 19 is able tocontrol the individual operating statuses of the field devices 10 and/or12 through the controller 17 by applying setting values and controlvalues to the controller 17.

The link module 15A obtains device information of the smartcommunication-compatible devices 10, for example, that are connected toI/O units 11, through the smart communication-compatible I/O units 11through the TCP/UDP communication route 16. A portion or the entirety ofthe device information (live list information) obtained can be stored ina memory (not shown), or the like, of the link module 15A. The linkmodule 15A can provide, to the device monitoring unit 15, a portion orthe entirety of the live list information through the TCP/UDPcommunication route 16 in response to a query from the device monitoringunit 15.

On the other hand, the link module 15A is able to receive responses,event notifications, and the like, from the smartcommunication-compatible devices 10, and able to send, to the devicemonitoring unit 15, through the TCP/UDP communication route 16, theresponses, event notifications, and the like, that have been received.Note that while in FIG. 1 and FIG. 2 the link module 15A is illustratedas being separate from the device monitoring unit 15, it may instead beincluded within the device monitoring unit 15.

The device monitoring unit 15, together with the link module 15A,performs monitoring, diagnostics, and the like, of the devices 10 thatare connected to the applicable I/O units 11 through communicating withthe smart communication-compatible I/O units 11 through the TCP/UDPcommunication route 16. As examples of monitoring and diagnostics thereare checks of the execution statuses of the processes of the devices 10,the statuses of the devices 10, and the like, and diagnostics, and thelike, of, for example, the timing with which maintenance and repairs arerequired on the device 10.

In order to perform the monitoring and diagnostics, in the devicemonitoring unit 15, the definitions used in, for example, engineeringtools (hereinafter also termed “device definition tools”), and the like,and device definition information (control device information) that havebeen set are stored in a memory (not shown), or the like, as a deviceinformation file.

By way of illustration, the device definition file may include, asnecessary, information such as smart communication protocol revisions,node numbers of the link module 15A, network address information for thelink modules 15A, and network address information, file numbers for theapplicable device definition files, I/O module numbers, slot numbers,device tags, device IDs, device types, device revisions, vendors, vendorIDs, model names, and the like, for the I/O units 11.

Note that the information set comprising the node number, the filenumber, the I/O module number, and the slot number may be used asinformation for specifying the route from the device monitoring unit 15to the device 10 (Route information).

The processes such as the various types of checks and diagnostics forthe devices 10 by the device monitoring unit 15 may include some or allof the processes (1) through (5), given as illustrative examples below.Note that these processes (1) through (5) shall be referred to as awhole by the term “loop check,” below.

(1) Device Existence Check

(2) Commissioning

(3) Analog Input (AI) Check

(4) Analog Output (AO) Check

(5) Progress Check (regarding the operations in (1) through (4), above)

(1) The “Device Existence Check” is a process for checking (making anOK/NG evaluation) the electrical connection status for a device 10 thatis connected to an I/O module 11 (hereinafter also termed the “deviceconnection status”) through the monitoring system, for example. Thecheck result is outputted to a monitor 156 (shown in FIG. 3), forexample, of the device monitoring unit 15. Non-limiting examples of“device connection statuses” include “Connected,” “Disconnected,” “NotConfigured,” “Unknown,” “Mismatch,” and the like. By way ofillustration, the device monitoring unit 15 may evaluate as “OK” if thedevice connection status is “Connected,” “Disconnected,” or “NotConfigured,” and may evaluate as “NG” if “Unknown” or “Mismatch.”

(2) “Commissioning” is a process for performing a consistency check(OK/NG), for example, of the existing device definition information thatis set in the device monitoring unit 15 using the engineering tools, andthe like, for controlling the devices 10, and the device information(live list information) obtained from the devices 10 through themonitoring system (for example, the link module 15A). Note that inregards to “Commissioning,” the device monitoring unit 15 is able toexecute a (2-1) Range Check and/or an (2-2) Output Value Check. The“Range Check” is a process for checking whether or not the upper limitvalues (high ranges) and/or lower limit values (low ranges) of thevariables set in the device 10 are correct, where the “Output ValueCheck” is a process for checking the output value of the device 10.Output values that are subject to checking include, for example,pressure values (PV), flow rate values (SV), temperature values (TV),and heat quantity values (QV).

(3) The “AI Check” is a process for specifying (controlling) the outputvalue (an analog DC signal between 4 and 20 mA) for the device 10through the monitoring system, and checking the analog input based onthe response (an analog output) of the device 10 to the specification.

(4) The “AO Check” is a process for setting (controlling) the outputvalue (an analog DC signal between 4 and 20 mA) for the device 10through the controlling system (the controller 17), and checking,through the monitoring system, the response (an analog output) of thedevice 10 to the setting.

(5) The “Progress Check” is a process for, for example, controlling,independent of the device 10, the check status (progress) for a portionor the entirety of the processes (operations) described above. Theprogress status information can be displayed on a monitor, or the like,used by an operator such as a process administrator or maintenancetechnician, or the like.

Note that the system may be such that the execution of a portion or theentirety of the “Commissioning,” “AI Check,” and “AO Check” is limitedto those devices 10 wherein the results of the “Device Existence Check”were “OK,” verifying that there is no problem in the connection status.This makes it possible to eliminate unnecessary checks, therebyincreasing the operating efficiency of the loop check.

(1-2) Hardware Configuration of the Device Monitoring Unit 15

The device monitoring unit 15 that executes some or all of the loopcheck, as illustrated in FIG. 3, for example, can be embodied using adata processing device such as a personal computer (PC), or the like.

The device monitoring unit 15 illustrated in FIG. 3, by way ofillustration, is provided with: a CPU 151, a RAM (random access memory)152; a ROM (read only memory) 153; a memory device 154, such as a harddisk; one or more interfaces (IF) 155A through 155D; a monitor 156; akeyboard 157, and a pointing device 158, such as a mouse.

The keyboard 157 and the pointing device 158 are examples of inputdevices by which an operator inputs information (such as, for example,device information or setting data used in the loop check, or the like)into the device monitoring unit 15.

The monitor 156 is a display device such as a liquid crystal display, aPDP (plasma display panel), an HMD (head-mounted display), or the like,for displaying data that is stored into the RAM 152, the ROM 153, and/orthe memory device 154, under the display control of the CPU 151. Notethat the monitor 156 may also be provided with an inputting device thatis able to input information, such as a touch panel, or the like.

The interfaces 155A through 155C are interfaces that are used forconnecting peripheral devices, such as, respectively, the monitor 156,the keyboard 157, and the pointing device 158. The interfaces, by way ofillustration, may use interfaces such as USBs, IEEE 1394, serialinterfaces, parallel interfaces, infrared, radio, or the like. Theinterface 155D is a communication interface for connecting the devicemonitoring unit 15 to, for example, a TCP/UDP communication route 16.

The memory device 154, by way of illustration, stores the devicemonitoring program for executing the loop check described above, settingdata (configuration data), and the like. The device monitoring programmay be provided in a form wherein it is recorded on a computer-readablerecording medium. Recording media includes, for example, hard disks,magnetic disks, magneto-optical discs, CD ROMs (compact disk read-onlymemories), DVDs (digital versatile disks), BDs (Blu-ray disks), ROMcartridges, RAM cartridges with battery backup, flash memory cartridges,non-volatile RAM cartridges, and the like. The device monitoring unit,which is an example of a computer, reads in, from the recording medium,the device monitoring program and the setting data, and sends them tothe memory device 154 and the RAM 152, for storage and use. Moreover,the device monitoring program may also be provided to the devicemonitoring unit 15 through, for example, the TCP/UDP communication route16.

Note that the “computer,” by way of illustration, is a concept thatincludes hardware and an operating system (OS), and may refer to thehardware operating under control of the operating system. Moreover, whenit is possible to operate the hardware using a program alone, withoutrequiring an operating system, this hardware may be positionedcorresponding to a “computer.” The hardware may include a calculatingdevice, such as a CPU, and a reading device that is able to read aprogram that is stored on a storage medium.

The device monitoring program includes program code by which to achieve,on the computer such as described above, functionality as the devicemonitoring unit 15. A portion of the functions may be achieved by theoperating system rather than by the program.

The ROM 153 is an example of a non-volatile storage medium, and stores aprogram and data for, for example, setting microcode to the CPU 151,initiating various portions, launching an operating system, or like,from the memory device 154, directing that a program be executed, andthe like, when the device monitoring unit 15 is started up.

The RAM 152 is an example of a volatile storage medium, and provides aworking area (working memory) for the CPU 151.

The CPU 151 is an example of a signal processor that is provided withcalculation processing capabilities. The CPU 151 deploys to the RAM 152,which is a working area, the device monitoring program and setting datathat is stored in the ROM 153 or the memory device 154, along withvarious types of inputted information obtained through the interfaces155A through 155C, and causes the computer to function as the devicemonitoring unit 15 through operating in accordance with the devicemonitoring program, and the like, that has been deployed. Note that anMPU or a DSP or ASIC may be used instead of the CPU 151.

(1-3) Functional Blocks of the Device Monitoring Unit 15

FIG. 4 shows a functional block diagram of a device monitoring unit 15.The device monitoring unit illustrated in FIG. 4 achieves a portion orthe entirety of the various portions (tools) 151-1 through 151-6 (whichmay also be termed the “loop checking tools,” below) through the CPU 151executing the device monitoring program in cooperation with the RAM 152,the ROM 153, and the memory device 154, as described above.

(1) The device existence checking portion (device existence checkingtool) 151-1

(2) The commissioning portion (commissioning tool) 151-2

(3) The AI checking portion (AI checking tool) 151-3

(4) The AO checking portion (AO checking tool) 151-4

(5) The progress checking portion (progress controlling tool) 151-5

Note that the commissioning portion 151-2 may be provided with functionsof a range checking portion (range checking tool) 151-6 and/or an outputvalue checking portion (output value checking tool) 151-7.

Moreover, the device monitoring unit 15 (CPU 151), at the time ofstartup, reads configuration data from, for example, the memory device154 into the RAM 152. The configuration data includes, by way ofillustration, data, and like, for specifying threshold values (forexample, tolerance threshold values) used in the pass/fail (OK/NG)evaluations in, for example, the “Range Checks,” “AI Checks,” and “AOChecks,” and the like, data output reading frequencies and intervals(periods), and the like.

The commissioning portion 151-2 (range checking portion 151-6), the AIchecking portion 151-3, and the AO checking portion 151-4 are able toexecute, respectively, a “Range Check,” an “AI Check,” and an “AOcheck,” based on the configuration data that has been read into the RAM152.

(1-4) Loop Checking by the Device Monitoring Unit 15

The loop checking by the device monitoring unit 15 can be executed atthe time of startup of the factory, plant, or the like (as illustratedin FIG. 5), or at the time of operation thereof (as illustrated in FIG.6). That is, the device monitoring unit 15 supports the smoothperformance of the startup operations or the continuing operations ofthe factory through the execution of checks of the connection statuses,the parameter setting statuses, and the like, of the field devices atthe time at which the factory or plant is started up, and during theoperation thereof, and checks of the proper operation of the fielddevices, and the like.

For example, at the time that a plant is started up, as illustrated inFIG. 5, the device monitoring unit 15 may execute the “Device ExistenceCheck,” the “Commissioning,” the “Range Check,” the “AI Check,” the “AOCheck,” and the “Output Value Check” through the device existencechecking portion 151-1, the commissioning portion 151-2, the AI checkingportion 151-3, and the AO checking portion 151-4.

On the other hand, during plant operation, as illustrated in FIG. 6, thedevice monitoring unit 15 may execute the “Device Existence Check,” the“Commissioning,” the “Range Check,” and the “Output Value Check” throughthe device existence checking portion 151-1, and the commissioningportion 151-2.

The details of the “Device Existence Check,” the “Commissioning”(including the “Range Check” and/or “Output Value Check”), the “AICheck,” the “AO Check,” and the “Progress Check” will be explaineditem-by-item, below.

The device monitoring unit 15, when the loop checking tool is activated,displays on a monitor 156 (illustrated in FIG. 3), for example, a screen(a Loop Checking Tool window) using a graphical user interface (GUI), asillustrated in FIG. 7, for example.

(1-4-1) Device Existence Check

The device existence check can be executed through the Loop CheckingTool window.

By way of illustration, a Search button 201, a Filter button 202, aReport (Generate Report) button 203, page switching buttons 204, aProgress Rate (Display Progress Rate) field 205, a Clear button 206, aSetting button 207, an Execute button 208, a Select All checkbox 209, aDevice List Display field 210, and a Status Sample Display field 211 areprovided in the Loop Checking Tool window illustrated in FIG. 7.

Additionally, as illustrated in FIG. 7, the Loop Checking Tool windowmay also be provided with tabs 221 through 225 for switching the variousfunctions (tools) for the “Device Existence Check,” the “Commissioning,”the “AI Check,” the “AO Check,” and the “Progress Check.”

By selecting (clicking) the Device List tab 221, the Commissioning tab222, the AI Check tab 223, the AO Check tab 224, or the Progress tab125, the selected tab is displayed in front of the other tabs in theLoop Checking Tool window.

The example display in FIG. 7 is an example display of the state whereinthe Device List tab 221 has been selected, making it possible to executethe “Device Existence Check” function (device existence checking portion151-1). Similarly, if the Commissioning tab 222, the AI Check tab 223,the AO Check tab 224, or the Progress tab 225 were to be selected, thenthe display would be as illustrated in FIG. 10, FIG. 13, FIG. 15, orFIG. 17, respectively. Note that instead of selecting the function(tool) by switching the tabs 221 through 225, pop-up windows, or thelike, corresponding to the respective functions that constitute the loopchecking tool may be displayed individually.

The Search button 201 can be used when, for example, specifying searchparameters (search keys) to search for a device 10. The device existencechecking portion 151-1 is able to display, in the Device List Displayfield 210, devices 10 that match (hit) the search parameters.Information for the route to the device 10 and the operation completionstatus can be used as search keys. The search keys can be stored in thedevice monitoring unit 15 (for example, the RAM 152 or memory device154, shown in FIG. 3), insofar as the loop checking tool is notterminated.

By way of illustration, the search parameters can be set through aSearch Parameter Setup screen (window) that uses the GUI. An exampledisplay of the Search Parameters Setup window is shown in FIG. 8. InFIG. 8, the search parameters can be set by specifying ranges for eachof the route information (for example, “Nodes,” “Files,” “I/O Modules,”and “Slots”). Moreover, the searching can be performed through, forexample, partial matches with character strings for the deviceinformation (“Tag,” “Device ID,” “Device Type,” “Device Revision,”“Vendor,” “Model,” and the like).

Next, in the example display in FIG. 7, the Filter button 202 is abutton for switching between a filtered display and showing all. In the“Filter” state, the “Device Existence Check” will display only thefiltered devices 10 in the Device List Display field 210. In the ShowAll state, the filter is removed and all devices are displayed in theDevice List Display field 210. At that time, the filtering by the searchparameters specified by the Search button may also be removed. However,the settings for the search parameters may be saved for later use.

When the Report button 203 is selected (for example, clicked), thedevice existence checking portion 151-1 generates the results of thedevice connection status check in the form of a file of a specificformat. An example of a file of a specific format is a CSV (CommaSeparated Value) file.

When a page switching button 204 is clicked, the device existencechecking portion 151-1 switches the page of the Device List Displayfield 210 that is displayed. For example, when the “<<” button 241 isclicked, then the first page is displayed, when the “>>” button 244 isclicked, then the last page is displayed, when the “<” button 242 isclicked, then the previous page is displayed, and when the “>” button243 is clicked, then the next page is displayed.

The Progress Rate Display field 205 is a field for displaying the rateof progress of the device existence check. The rate of progress can bedisplayed as, for example, the ratio of the devices 10 for which thedevice existence check has been completed, in relation to all of thedevices 10.

When the Clear button 206 is clicked, then the device existence checkingportion 151-1 clears the device connection status check results for theselected devices 10. The Clear button 206 can be placed into a state(the Enabled state) wherein I/O modules 11 for which the deviceexistence check has been completed can be subject to selectionoperations if selected.

When the Setting button 207 is clicked, the device existence checkingportion 151-1 opens a dialog for setting up parameters.

When the Execute button 208 is clicked, the device existence checkingportion 151-1 executes the “Device Existence Check.” The system may besuch that the Execute button 208 may be switched into a Cancel buttonduring the execution of the “Device Existence Check.” When the Cancelbutton is clicked, the device existence checking portion 151-1 willcancel the execution of the “Device Existence Check.” Note that thesystem may be such that the Cancel button is provided separately fromthe Execute button 208.

When the Select All checkbox 209 is checked, the device existencechecking portion 151-1 puts into the selected state all of the devices10 on the page that is currently displayed in the Device List Displayfield 210. When the check in the checkbox 209 is cleared, then thedevice existence checking portion 151-1 clears the Select All.

By way of illustration, the existence check results (the deviceconnection statuses) of the devices 10 are listed in the Device ListDisplay field 210. If an entry (or an icon) for any of the devices 10 isselected, then the device existence checking portion 151-1 may display,in a tooltip, or the like, device information such as the device tag, orthe like. The device connection statuses may be displayed by icons inthe Status Sample Display field 211, and as illustrated in Table 1,below.

Device Connection Statuses Display Status (Icon) Explanation ConnectedBlue There is a definition in the device definition information, and thedefined device is connected. Dis- Grey There is a definition in thedevice definition connected information, and the defined device is notconnected. Unknown Aqua There is no definition in the device definitioninformation, but a device is connected. Mismatch Red There is adefinition in the device definition information, but a device that isdifferent from the definition is connected. No Config- There is nodefinition in the device definition uration information, and no deviceis connected.

Note that the device existence checking portion 151-1, by way ofillustration, evaluates as “OK” if the device connection status is“Connected,” “Disconnected,” or “Not Configured,” and evaluates as “NG”if “Unknown,” or “Mismatch.” Entries wherein the status check result is“NG” may be displayed with the background color different from the colorof other entries (for example, red) to provide a highlighted display.The date and time at which the device connection status was checked mayalso be displayed in the device status list.

FIG. 9 shows an example of an operation flowchart for the “DeviceExistence Check.”

First, the operator clicks the Search button 201 to call the SearchParameters Setup window as illustrated in FIG. 8, and, in this SearchParameters Setup window, the operator sets up the search parameters forthe applicable devices 10, for executing the “Device Existence Check”(Process P101).

The device existence checking portion 151-1 searches the devicedefinition information based on the search parameters that have been setup in the Search Parameters Setup window, and displays, in the DeviceList Display field 210, the devices 10 that match the search parameters.

Thereafter, when an Execute event for the “Device Existence Check” isproduced through the Execute button 208 being clicked, the devicemonitoring unit 15 (the device existence checking portion 151-1)performs device connection status queries on the link module 15A for thedevices 10 that have been retrieved.

A smart communication command (a device connection status acquisitioncommand), for example, may be used in this query. The command may beissued in units of individual devices 10, or may be issued in units(groups) of I/O units 11 to which the devices 10 are connected.

If the commands are issued in units of I/O units 11, then it is possibleto check the device connection statuses grouped by units of I/O units11, thus making it possible to achieve an increase in speed in the“Device Existence Check.” Note that the processes regarding the queriesmay be executed through multithreading. Doing so makes it possible tominimize the effect on the user interface and other systems during thequery process as well.

The link module 15A that has received the device connection statusacquisition command sends (responds), to the device monitoring unit 15,the live list information that is acquired and stored from the devices10, through the I/O units 11.

The device monitoring unit 15 compares the live list informationreceived from the link module 15A to device definition information thatis, for example, stored in the RAM 152, to evaluate the connectionstatuses of the devices 10 based on the comparison results and criteriasuch as illustrated in Table 1 (Process P102). Partial informationelements in the live list information and in the device definitioninformation, for example, the “Device Tag” and the “Device Type,” may beused in this comparison.

By way of illustration, the evaluation results may be displayed by thedevice unit using icons of different colors, as shown in Table 1 andFIG. 7. When an icon is, for example, double-clicked using the mouse, orthe like, the applicable live list information may be displayed as atooltip, or the like.

By way of illustration, the items displayed may include, for example,the device tags, the device types, the device revisions, the vendornames, the model names, the smart communication protocol revisions, andthe like. This makes it easy for the operator to identify, for example,the statuses of the device 10 that cause the “Device Existence Check”results to be “NG” (that is, the causes of the NG).

Note that the device existence checking portion 151-1 may evaluate thedevice connection status to be a “Mismatch” if the “Device Tag and/orthe “Device Type” in the device information recorded in the link module15A is different from that of the device 10 that is actually connected.Consequently, the device existence checking portion 151-1 may evaluatethe device connection status to be “Connected” (OK) even if there is adiscrepancy in the “Device ID” or the “Device Revision” in the deviceinformation.

The device monitoring unit 15 (device existence checking portion 151-1)checks whether or not all of the device connection statuses are “OK”(“Connected” or “Disconnected”) for all of the devices 10 that areconnected to the same I/O unit 11 (Process P103). If all of the deviceconnection statuses are evaluated as “OK” (Route Y in Process P103),then the device existence checking portion 151-1 defines the “DeviceExistence Check” result as “OK.”

If the Report button 203 is clicked, then the device existence checkingportion 151-1 generates a report (Process P104).

On the other hand, if the results of the device connection status checksare not all evaluated as “OK” (that is, if there is a “Unknown Device”or “Mismatch”), then the device existence checking portion 151-1 definesthe “Device Existence Check” result for the applicable devices 10 as“NG.” Note that if there is an error on a level higher than that of theI/O unit 11, then the evaluation may be “Mismatch” for all of thedevices 10 that are connected to the applicable I/O unit 11.

The device monitoring unit 15 (device existence checking portion 151-1)displays the evaluation results, described above, in the Device ListDisplay field 210. Note that for those devices 10 for which the “DeviceExistence Check” result is “NG,” the operator will correct the devicestatus by, for example, correcting the device information (from route Nin Process P103 through Process P105). The “Device Existence Check” isexecuted repeatedly until there are no devices 10 for which the “DeviceExistence Check” result is “NG” (Route N in process P103).

As described above, the device monitoring unit 15 is able to check,through a monitoring system, the connection statuses of the devices 10that are connected to the I/O units 11, through the functions of thedevice existence checking portion 151-1. Consequently, the operator isable to check easily that the connection statuses of the devices 10 arecorrect at the time that the factory or plant is started up, duringoperation thereof, and the like, making it possible to perform thefactory startup operations and continuing operations smoothly. Theresult is a major contribution to a reduction in the operating load onthe operators, a shortening of lead times (and, by extension, areduction in power consumption, and the like), and to ensuring safety ofthe factory, plant, or the like.

(1-4-2) Commissioning

As illustrated in FIG. 10, for example, the “Commissioning” function(the commissioning portion 151-2) can be executed from the state whereinthe Commissioning tab 222 has been selected in the Loop Checking Toolwindow. In the state wherein the Commissioning tab 222 is displayed, thebuttons and fields assigned identical codes to those in FIG. 10 providethe corresponding functions in “Commissioning.”

For example, in the state wherein the Commissioning tab 222 isdisplayed, it is possible to add and use as search parameters (searchkeys), in a device search that uses the search button 201, theinformation used in “Commissioning” as well. The search key may be heldin the device monitoring unit 15 as long as the loop check tool has notfinished.

When the Report button 203 is clicked, the commissioning portion 151-2produces the results of the “Commissioning” as a file of a specificformat, such as a CSV file.

The Progress Rate Display field 205, by way of illustration, displaysthe proportion of the devices 10 that have completed the execution of“Commissioning” to all of the devices 10.

When the Clear button 206 is clicked, the commissioning portion 151-2clears the commissioning results that are displayed in the DeviceDetails pane 301.

When the Execute button 208 is clicked, the commissioning portion 151-2executes the “Commissioning” and/or the “Output Value Check” on thedevices 10 that are displayed in the Device List Display field 300. Thesystem may be such that the Execute button 208 may be converted into aCancel button while the “Commissioning” and/or the “Output Value Check”is being performed. When the Cancel button is clicked, the commissioningportion 151-2 will cancel the execution of the “Commissioning” and/orthe “Output Value Check.” Note that the system may be such that theCancel button is provided separately from the Execute button 208.

A Device List Display field 300 for displaying a device list may beprovided in the top portion of the Commissioning tab 222. The itemsdisplayed in this field 300 are, by way of illustration, node numbers,file numbers, I/O module numbers, slot numbers, device tags, along withmodel names, evaluation results for the “Commissioning” and/or the“Output Value Checks,” the date and time, and the like.

Entries wherein the “Commissioning” and/or “Output Value Check” resultis “NG” may be displayed with the background color different from thecolor of other entries (for example, red) so as to be easily noticeableto the operator.

It is possible to determine freely the number of entries that can bedisplayed on one page of the Device List Display field 300 (that is, thenumber of lines in the list view). As one non-constraining example, thenumber of devices that can be displayed in a single page is a maximum of80. If the number of devices to be displayed is greater than the maximumnumber that can be displayed on a single page, then, for example, avertical scrollbar may be displayed on the right edge of the Device ListDisplay field 300, in a system wherein it is possible to scroll todisplay all of the devices in the page.

A Device Details field 300, for displaying detailed information aboutdevices, may be provided in the bottom portion of the Device ListDisplay field 300 in the Commissioning tab 222. By way of illustration,detailed information about the device 10 that is currently selected inthe Device List Display field 300 is displayed in the Device Detailspane 301.

By way of illustration, the items displayed in the Device Details pane301 are, for example, the device tags, the device IDs, the device types,the device revisions, the vendors, the vendor IDs, the model names, thesmart communication protocol revisions, range information (high rangesand/or low ranges), and so forth.

A Device Definition Information field 309 for displaying the devicedefinition information that is defined by an engineering tool, or thelike, and a Live List Information field 310, for displaying live listinformation obtained from a device 10 using a smart communicationcommand may, be provided in the Device Details pane 301. These fields309 and 310 may be displayed, for example, lined up side-by-side, makingit easy to discern visually whether or not the respective informationmatch each other.

If the “Device ID” and/or “Device Revision” are blank in the DeviceDefinition Information field 309 (that is, not yet defined), then theevaluation results may be defined as “OK” if the items other than thisinformation match, and the undefined information may be copied from thelive list information. This copying either may be performedautomatically or may be performed through clicking, for example, a Copybutton 302. If the “Device ID” and/or “Device Revision” are not blank,then this information may be added to be subject to evaluation in the“Commissioning.”

When the Copy button 302 is clicked, the Commissioning portion 151-2copies the “Device ID” to the device definition information from thelive list information of the selected device 10. When the Copy button302 is clicked in the “Output Value Check,” the output value checkingportion 151-7 will copy, to the device definition information, the “PV,”“SV,” “TV,” “QV,” and the like, from the live list information.

When the Execute button 303 is clicked, the commissioning portion 151-2executes the “Commissioning” and/or the “Output Value Check” regardingthe selected device 10. The device definition information defined by anengineering tool, or the like, and the live list information obtainedfrom the device 10 using a smart communication command are comparedthrough the execution of the “Commissioning.”

Note that the system may be such that the Execute button 303 may beconverted into a Cancel button while the “Commissioning” and/or the“Output Value Check” is being performed. When the Cancel button isclicked, the commissioning portion 151-2 and/or the output valuechecking portion 151-7 will cancel the execution of the “Commissioning”and/or the “Output Value Check.” Note that the system may be such thatthe Cancel button is provided separately from the Execute button 303.

The commissioning portion 151-2 can send a Squawk command, which is oneof the smart communication commands, to the selected device 10 when theSquawk button 304 is clicked. Doing so makes it possible to check for avisible, audible, and/or mechanical response that is unique to thedevice 10, indicating the reception of the command. Note that if thedevice 10 does not support a Squawk command, then the commissioningportion 151-2 will display an error message on the monitor 156, or thelike.

When the “Commissioning” radio button 305 is checked, the CPU 151enables the “Commissioning” function. When the “Output Value Check”radio button 306 is checked, the CPU 151 enables the “Output ValueCheck” function.

By way of illustration, the evaluation results for the “Commissioning”and/or the “Output Value Check” of the devices 10 that are selected aredisplayed in the Evaluation Results field 307. For example, if theresults for “Commissioning” are all matches, then “OK” is displayed asthe evaluation results. If there is a mismatch in the result of“Commissioning,” then “NG” will be displayed as the evaluation result.If the evaluation result is “NG” then the item wherein there is amismatch may be displayed in a different display color (for example,displayed in red) so as to be noticed easily by an operator.

By way of illustration, the dates and times (yyyy/MM/dd HH:mm:ss) of the“Commissioning” and/or “Output Value Check” performed most recentlyregarding the selected devices 10 are displayed in the Date and Timefield 308.

Note that the Device Definition Information field 309 may be providedwith a Range Information Setting field 311, and a Conversion Factorfield 312, for setting a conversion factor for the range information(which is, for example, 1.0 by default) may be provided in the field311. The conversion factor is the factor for converting to the actualvalue from a setting value in a distributed controlling system (DCS)(for example, a controller 17). The conversion factor may be stored,included in the live list information, at the completion of execution of“Commissioning.”

FIG. 11 shows an example of an operation flowchart for the“Commissioning.”

First, the operator clicks the Search button 201 to call the SearchParameters Setup window as illustrated in FIG. 8, and, in this SearchParameters Setup window, the operator sets up the search parameters forthe applicable devices 10, for executing the “Commissioning” (ProcessP201).

The commissioning portion 151-2 searches the device definitioninformation based on the search parameters that have been set up in theSearch Parameters Setup window, and displays, in the Device List Displayfield 300, the devices 10 that match the search parameters.

Thereafter, when either the Execute button 208 that is provided in theLoop Checking Tool window (above the Device List Display field 300) orthe Execute button 303 that is provided in the Device Details pane 301is clicked, the commissioning portion 151-2 performs commissioning forthe devices 10 that are displayed in the Device List Display field 300(Process P202).

For example, the commissioning portion 151-2 queries the link module 15Afor device information for a device 10. It is possible to use a smartcommunication command (the Commissioning Data Collecting command), forexample, in this query. The command may be issued in units of individualdevices 10, or may be issued in units (groups) of I/O units 11 to whichthe devices 10 are connected.

If the commands are issued in units of I/O units 11, then it is possibleto perform the commissioning grouped by units of I/O units 11, thusmaking it possible to achieve an increase in speed in the“Commissioning.” Note that the processes regarding the queries may beexecuted through multithreading. Doing so makes it possible to minimizethe effect on the user interface and other systems during the queryprocess as well.

When the device information (the live list information) for a device 10is obtained, then the commissioning portion 151-2 compares the devicedefinition information and the live list information obtained from thedevice 10, to evaluate whether or not the two match (Process P203).

If the evaluation results are all “OK” (Route Y in Process P203) and theReport button 203 is clicked, then the commissioning portion 151-2generates a report for the results of the “Commissioning” as, forexample, a CSV file (Process P204).

Note that even if the “Commissioning” result is “NG” (Route N in ProcessP203), the device monitoring unit 15 need not necessarily update thedevice definition information, overwrite the live list information, orthe like. If necessary, it is possible to use the device definition toolin regards to updating device definition information (Processes P205 andP206). The overwriting of the live list information (the deviceinformation possessed by the device 10) can be performed through callingthe Device Type Manager) (DTM) from a device administering tool (notshown) in the device monitoring unit 15 (Processes P207 and P208).

As described above, the device monitoring unit 15 is able to checkeasily, through the monitoring system, the match between devicedefinition information, which is set up in advance, and deviceinformation of a device 10 that is connected to an I/O unit 11, usingthe functions of the commissioning portion 15-12.

Consequently, it is possible for the operators to perform the factorystartup operations and continuing operations smoothly. The result is amajor contribution to a reduction in the operating load on theoperators, a shortening of lead times (and, by extension, a reduction inpower consumption, and the like), and to ensuring safety of the factory,plant, or the like.

(1-4-2-1) Range Check

The device monitoring unit 15 (CPU 151) is able to perform checks on therange settings (high ranges and low ranges) of the devices 10 (rangechecks) at the time that “Commissioning” is performed, throughfunctioning as the range checking portion 151-6 (shown in FIG. 4). Ofthe analog input (AI) and the analog output (AO) of the device 10, the“Range Check” focuses on the range settings for at least the AI.

The CPU 151 (the range checking portion 151-6, shown in FIG. 4) comparesa value wherein a range setting value in the device definitioninformation is multiplied by a conversion factor (which by default is,for example, 1), to a range setting value in the live list informationobtained from the device 10. The range checking portion 151-6 evaluatesthe result as “OK” if the two match within the tolerance error range,and “NG” if they are different, and displays the evaluation result in,for example, an Evaluation Results field 307. Note that rangeinformation set in a controller 17 may be included as subject tocomparison with the range information in the device definitioninformation in the “Range Check.”

(1-4-2-2) Output Value Check

When an Execute button 208 or 303 is clicked when the “Output ValueCheck” radio button 306 is checked in the Commissioning tab 222, thenthe device monitoring unit 15 (the CPU 151) executes checks on the PVs(pressure values), SVs (flow rate values), TVs (temperature values), andQVs (heat quantity values) through functioning as the output valuechecking portion 151-7 (shown in FIG. 4). Note that an exampleillustrating a screen (window) wherein the “Output Value Check” radiobutton 306 is checked is shown in FIG. 12.

The command values for the PV, SV, TV, QV, and the like, that aresubject to comparison may be inputted as appropriate by the operator.The specification values are stored in the RAM 152 or the memory device154. When the Copy button 302 is clicked, the output values for, forexample, PV, SV, TV, QV, and the like, obtained from the device 10through the monitoring system, may be copied (stored) to, for example,the RAM 152 or the memory device 154, and these output values may beused as specification values.

Moreover, storing the output values makes it possible for the devicemonitoring unit 15 (the output value checking portion 151-7) to performchecks on the various output values at the time at which the operationof the device 10 is halted for operations such as process maintenanceand inspection, or at the time at which the device 10 is restarted. Thepoint in time at which the operation of the device 10 is stopped is anexample of a first time point, and the point in time at which theoperation of the device 10 is restarted is an example of a second timepoint.

Moreover, the RAM 152 and the memory device 154 are examples of memoriesfor storing the analog output values that are outputted by the devices10 to the I/O modules 11 (analog communication routes) at the first timepoint, received from the devices 10 through the digital communicationroute 16 of the monitoring system.

Through this, the analog output value that is outputted from a device 10to an I/O module 11 (an analog communication route) at the second timepoint, received from the device 10 through the digital communicationroute 16, is compared, by the output value checking portion 151-7, tothe stored analog output value from the first time point. It is possiblefor the output value checking portion 151-7 to check, through thiscomparison, whether or not the analog output operation of the device 10is correct.

For example, let us assume that the analog output value at the point intime at which the operation of the device 10 is restarted, as an exampleof a second time point, is quite different, exceeding the tolerancerange, in relation to the analog output value at the point in time atwhich the operation of the device 10 was stopped, which is an example ofa first time point. In this case, the output value checking portion151-7 would evaluate the result of the “Output Value Check” as “NG.” Onthe other hand, if the discrepancy between the analog output values atthese two points in time is within the tolerance range, then the outputvalue checking portion 151-7 will evaluate the “Output Value Check”result as “OK.”

When the Report button 203 is clicked after the completion of an “OutputValue Check,” as described above, then the CPU 151 (the output valuechecking portion 151-7) will create a report that includes the outputvalue check settings (the conversion factors, and the PVs, SVs, TVs andQVs of the device definition information), the output values, the checkresults, the dates and times, and the like.

The operator, based on this report, is able to tell whether or not somesort of problem has occurred in the analog output operation of thedevice 10 during an operation such as, for example, process maintenanceor inspection, or the like, enabling the operator to execute appropriatecountermeasures.

(1-4-3) AI Check

As already described, the “AI Check” is a process that checks the analoginput of the device 10 based on a response by the device 10 to aninstruction from the I/O module 11, through the monitoring system, thatspecifies, to the device 10, an output value (an analog DC signalbetween 4 and 20 mA).

The “AI Check” function (the AI checking portion 151-3, shown in FIG. 4)is activated through the selection of the AI Check tab 223 in the LoopChecking Tool window, such as illustrated, for example, in FIG. 13. Inthe state wherein the AI Check tab 223 is displayed, the buttons andfields that are assigned codes that are identical to those in FIG. 7provide the corresponding functions to the “AI Check.”

For example, the information for the route to the device 10 can be usedin the search parameters (search key) for device searching by the Searchbutton 201 in the state that the AI Check tab 223 is displayed. Thesearch key may be held in the device monitoring unit 15 as long as theloop check tool has not finished.

When the Report button 203 is clicked, the AI checking portion 151-3generates the “AI Check” result in a report file of a specific format,such as CSV.

The Progress Rate Display field 205 displays, for example, theproportion of the devices 10 that have completed the execution of “AICheck” to all of the devices 10.

When the Clear button 206 is clicked, the AI checking portion 151-3clears the results for the “AI Check” of the device 10 that is selectedin the device list that is displayed as the searching result in theDevice List Display field 403 of the AI Check tab 223. The Clear button206 may be placed into an enabled state wherein it can receive aselection operation when a device 10 wherein the result of the “AICheck” is not blank is selected.

When the Execute button 208 is clicked, the AI checking portion 151-3executes the “AI Check” of the devices 10 that are selected in thedevice list that is displayed as the searching result in the Device ListDisplay field 403 of the AI Check tab 223. The system may be such thatthe Execute button 208 may be switched into a Cancel button during theexecution of the “AI Check.” When the Cancel button is clicked, the AIchecking portion 151-3 will cancel the execution of the “AI Check.” Notethat the system may be such that the Cancel button is providedseparately from the Execute button 208.

The AI Check tab 223 may be provided with a Checkpoint Count Setup menu401 and a Round Trip checkbox 402.

The Checkpoint Count Setup menu 401 is used in order to specify thenumber of points (N points, where N is a whole number) for the “AICheck” that will be performed in relation to the device 10. For example,when the Checkpoint Count Setup menu 401 is clicked, point countcandidates of 3 points (3 PTS) and 5 points (5 PTS) may be displayed asa pull-down menu, enabling one of these to be selected.

The Round Trip checkbox 402 is used in order to specify whether toperform the “AI Check” on the device 10 in only the uplink direction(the direction from the device 10 to the I/O module 11), or to performit in a round trip between the device 10 and the I/O module 11. When acheck is placed in the Round Trip checkbox 402, then “Round Trip” isspecified.

As a non-limiting example, when “3 points” is selected in the CheckpointCount Setup menu 401 and a check is placed in the Round Trip checkbox402, the AI checking portion 151-3 applies, to the device 10, a total offive points worth of Output commands, 4 mA→12 mA→20 mA→12 mA→4 mA, tocheck the actual analog output values of the devices 10 in relation toeach of these Output commands.

By way of illustration, an error threshold value (%), output value readdelay time, output value read count, and the like, are included in thesetup data used in the “AI Check.”

The devices 10 that are displayed in the Device List Display field 403of the AI Check tab 223 may be limited to devices 10 that are connectedto I/O modules 11 that are able to provide analog input to the device10. By way of illustration, the display items in the Device List Displayfield 403 are, for example, device tags, specification values, outputvalues from the devices 10, input values from the I/O modules 11 (theitems marked as “Xbus” in FIG. 13), the results of the AI check, datesand times, and the like. Device entries wherein the “AI Check” result is“NG” may be displayed with a different background color (for example,red) to provide a highlighted display.

FIG. 14 shows an example of an operation flowchart for the “AI Check.”

First, the operator clicks the Search button 201 to call the SearchParameters Setup window as illustrated in FIG. 8, and, in this SearchParameters Setup window, the operator sets up the search parameters forthe applicable devices 10, for executing the “AI Check” (Process P301).

The AI checking portion 151-3 searches the device definition informationbased on the search parameters that have been set up in the SearchParameters Setup window, and displays, in the Device List Display field403, the devices 10 that match the search parameters.

Following this, the operator selects entries for devices 10 for which toperform the “AI Check” from the device list that is displayed in theDevice List Display field 403, and selects, from the Checkpoint CountSetup menu 401, the number of checkpoints (3 points or 5 points) for the“AI Check” for the selected devices 10 (Process P302). Moreover, theoperator puts a check into the Round Trip checkbox 402 if the “AI Check”is to be performed with a “Round Trip” (Process P303).

The AI checking portion 151-3 sets the electric current value for theOutput command for the device 10 following the setup set forth above(Process 304). For example, if the Output command is 0%, then theelectric current value is set to 4 mA, if 50%, then 12 mA, or if 100%,then 20 mA. The Output command may use a smart communication command.

The AI checking portion 151-3 sends the Output command for the device 10to the TCP/UDP communication route 16, and then waits for a specifictime interval (the AI check output read delay time) (Process P305). Thisdelay time can be set to a time in accordance with the time required forstabilization of the analog DC signal that is outputted to the I/O unit11 by the device 10 that has received the Output command.

The Output command, which is a digital signal, is sent to the device 10through smart communications through the smart communications processingportion 115 (the NIC 1151, the calculating portion 1152, the smartcommunications modem 1154, the separating/superimposing portion 1155,and the interface 1156) of the I/O module 11.

The device 10 (the calculating portion 101) outputs an analog DC signalto the I/O module 11 with an electric current value specified by theOutput command received, through smart communication, from the I/Omodule 11. Note that the calculating portion 101 stores to the memory104, for example, the electric current value specified by the Outputcommand (a digital setting value obtained through the smartcommunications modem 107).

On the other hand, after the AI check output read delay time haselapsed, the device monitoring unit 15 (the AI checking portion 151-3)sends, to the TCP/UDP communication route 16, a smart communicationcommand (a Read command) for acquiring at the electric current valuethat is outputted to the analog communication route to the I/O module 11from the interface 108 after DA conversion by the DAC 103, for theelectric current value (the digital setting value) that is stored in thememory 104 for the device 10 (Process P305).

The Read command is received by the smart communications processingportion 115 of the I/O module 11 through the TCP/UDP communication route16. The smart communications processing portion 115 (the calculatingportion 1152) sends the received Read command to the device 10 throughsuperimposing it, as two different frequency signals, onto the analog DCsignal to the device 10, through the smart communications modem 1154 andthe separating/superimposing portion 1155.

The two different frequency signals that indicate the Read command areseparated from the analog DC signal by the separating/superimposingportion 105 of the device 10, and converted (demodulated) into theoriginal digital signal by the smart communications modem 107, and theninputted into the calculating portion 101. The calculating portion 101,upon receipt of the Read command through smart communications from theI/O module 11 in this way, reads out the electric current value (thedigital setting value) from the memory 104, and applies this electriccurrent value to the smart communications modem 107. As a result, thedigital setting value for the electric current value that has been readout from the memory 104 is converted (modulated) into the two differentfrequency signals corresponding to the digital value by the smartcommunications modem 107, and is superimposed onto the analog DC signalto the I/O module 11 by the separating/superimposing portion 105, to besent to the I/O module 11.

The two different frequency signals are received by the smartcommunications processing portion 115 (the interface 1156) of the I/Omodule 11, are separated from the analog DC current by theseparating/superimposing portion 1155, are converted into the respectivecorresponding digital values (that is, the digital setting value for theelectric current value, described above) by the smart communicationsprocessing portion 115, and are received by the calculating portion1152. The calculating portion 1152 sends the received electric currentvalue through the NIC 1151 and the TCP/UDP communication route 16 to thedevice monitoring unit 15. In this way, the device monitoring unit 15obtains the electric current value of the analog DC signal that isoutputted to the I/O module 11 by the device 10 through the analogcommunication route, as a digital value prior to the DA conversion bythe DAC 103.

Additionally, the device monitoring unit 15 (the AI checking portion151-3), in cooperation with the link module 15A, communicates with theI/O module 11 (for example, the calculating portion 1152 of the smartcommunications processing portion 115), to obtain, for example, the ADconversion value of the ADC 112, as the electric current value for theanalog DC signal that is actually inputted from the device 10 into theI/O module 11 (Process P306). The AD conversion value of the ADC 112 canbe provided to the device monitoring unit 15 through, for example,sending, from the NIC 1151 to the TCP/UDP communication route 16, the ADconversion value obtained through, for example, the calculating portion1152 communicating with the calculating portion 111 (communicationbetween CPUs).

The device monitoring unit 15 (the AI checking portion 151-3), ifnecessary, may repeat a specific number of times (the AI check outputread count) obtaining of the electric current value that is applied tothe DAC 103 of the device 10 (hereinafter termed also the “device outputvalue”) (Process P305), and obtaining of the AD conversion value of theanalog DC signal that is inputted from the device 10 into the I/O module11 (hereinafter termed also the “I/O module input value”). The AIchecking portion 151-3 takes the respective means of the device outputvalues and I/O module input values that are obtained through theserepetitions. Taking the averages can increase the evaluation accuracy ofthe “AI Check.”

Following this, the device monitoring unit 15 (the AI checking portion151-3) repeats the aforementioned processes P304 through P306 for thecheckpoint count specified in the Checkpoint Count Setup menu 401 (RouteN in the Process P307).

When the aforementioned repetitions have been completed (Route Y inProcess P307), if the “Round Trip” “AI Check” is specified (Route Y inProcess P308), the AI checking portion 151-3 follows the checkpoints inthe reverse sequence and repeats the processes P304 through P308 until0% is reached. For example, in the case of a 3-point round trip, thechecks are executed in the sequence of 0%→50%→100%→50%→0%.

Once the “Round Trip” checks have been completed (Route Y in ProcessP309), the AI checking portion 151-3 repeats the processes P304 throughP309 until the “AI Check” has been completed for all of the devices 10that are subject to the “AI Check” (Route N in Process P310).

Once the “AI Check” has been completed for all of the devices 10 (RouteY in Process P310), then the AI checking portion 151-3 compares thespecification values for the devices 10 to the device output values andthe I/O module input values.

If the comparison result is that the device output values and I/O moduleinput values are within a specific tolerance error ranges (the AI checkerror threshold values (%)) for the respective specification values,then the AI checking portion 151-3 evaluates the “AI Check” result as“OK,” but if not within the tolerance error range, then the evaluationwill be “NG.”

Moreover, when the Report button 203 is clicked, the AI checking portion151-3 produces a report file of the “AI Check” results in a specificformat, such as CSV (Process P311). By way of illustration, the reportfile may include the AI check settings (point count, round trip, etc.),the specification values from the device monitoring unit 15, the deviceoutput values, the I/O module input values, the evaluation results, thedates and times, and the like.

As described above, the device monitoring unit 15 is able to check,through the monitoring system, for the proper operation of the device 10in relation to the analog input, through the functions of the AIchecking portion 101-3. Consequently, it is possible for the operator toperform the factory started operations smoothly, resulting in a majorcontribution to a reduction in the operating load on the operators, ashortening of lead times (and, by extension, a reduction in powerconsumption, and the like), and to ensuring safety of the factory,plant, or the like. Doing so makes it possible to reduce the maintenanceand operating overhead on the operators.

Moreover, the device monitoring unit 15 can obtain a device output valueand an I/O module input value through the monitoring system, to comparethe two, and thus can check for the proper operation of the DAC 103and/or the ADC 112 of the I/O module 11. Moreover, it is possible tocheck the status (Normal/Fault) of the communication through the digitalcommunication route 16 and the status (Normal/Fault) of thecommunication through the analog communication route between the device10 and the I/O unit 11.

(1-4-4) AO Check

As already described, the “AO Check” is a process that sets (controls),through the monitoring system (the controller 17), an output value (ananalog DC signal between 4 and 20 mA) for the device 10 and checks theanalog output of the device 10 based on the response by the device 10 tothat setting.

The “AO Check” function (the AO checking portion 151-4, shown in FIG. 4)is placed into an executable state through the selection of the AO Checktab 224 in the Loop Checking Tool window, such as illustrated, forexample, in FIG. 15. In the state wherein the AO Check tab 224 isdisplayed, the buttons and fields that are assigned codes that areidentical to those in FIG. 7 provide the corresponding functions to the“AO Check.”

For example, the information for the route to the device 10 can be usedin the search parameters (search key) for device searching by the Searchbutton 201 in the state that the AO Check tab 224 is displayed. Thesearch key may be held in the device monitoring unit 15 as long as theloop check tool has not finished.

When the Report button 203 is clicked, the AO checking portion 151-4generates the “AO Check” result in a report file of a specific format,such as CSV.

The Progress Rate Display field 205 displays, for example, theproportion of the devices 10 that have completed the execution of “AOCheck” to all of the devices 10.

When the Clear button 206 is clicked, the AO checking portion 151-4clears the results for the “AO Check” of the device 10 that is selectedin the device list that is displayed as the searching result in theDevice List Display field 503 of the AO Check tab 224. The Clear button206 may be placed into an enabled state wherein it can receive aselection operation when a device 10 wherein the result of the “AOCheck” is not blank is selected.

When the Execute button 208 is clicked, the AO checking portion 151-4executes the “AO Check” of the devices 10 that are selected in thedevice list that is displayed as the searching result in the Device ListDisplay field 503 of the AO Check tab 223. The system may be such thatthe Execute button 208 may be switched into a Cancel button during theexecution of the “AO Check.” When the Cancel button is clicked, the AOchecking portion 151-4 will cancel the execution of the “AO Check.” Notethat the system may be such that the Cancel button is providedseparately from the Execute button 208.

The AO Check tab 224 may be provided with a Checkpoint Count Setup menu501 and a Round Trip checkbox 502.

The Checkpoint Count Setup menu 501 is used in order to specify thenumber of points (N points) for the “AO Check” that will be performed inrelation to the device 10. For example, when the Checkpoint Count Setupmenu 501 is clicked, point count candidates of 3 points (3 PTS) and 5points (5 PTS) may be displayed as a pull-down menu, enabling one ofthese to be selected. Note that the number of checkpoints that can beset in the “AO Check” may or may not be equal to the number in the caseof the “AI Check.”

The Round Trip checkbox 502 is used in order to specify whether toperform the “AO Check” on the device 10 in only the uplink direction, orto perform it in a round trip. When a check is placed in the Round Tripcheckbox 502, then “Round Trip” is specified.

As a non-limiting example, when “3 points” is selected in the CheckpointCount Setup menu 501 and a check is placed in the Round Trip checkbox502, the AO checking portion 151-4 checks a total of five points worthof output values of the device 10, 4 mA→12 mA→20 mA→12 mA→4 mA.

By way of illustration, an error threshold value (%), AO check readinterval (period), and the like, are included in the setup data used inthe “AO Check.”

The devices 10 that are displayed in the Device List Display field 503of the AO Check tab 224 may be limited to devices 10 that are connectedto I/O modules 11 that are able to receive analog output from the device10. By way of illustration, the display items in the Device List Displayfield 503 are, for example, device tags, specification values, inputvalues from the devices 10 (the output values of the I/O modules 11; theitems marked as “Xbus” in FIG. 15), the results of the AO check, datesand times, and the like. Device entries wherein the “AO Check” result is“NG” may be displayed with a different background color (for example,red) to provide a highlighted display.

FIG. 16 shows an example of an operation flowchart for the “AO Check.”

First, the operator clicks the Search button 201 to call the SearchParameters Setup window as illustrated in FIG. 8, and, in this SearchParameters Setup window, the operator sets up the search parameters forthe applicable devices 10, for executing the “AO Check” (Process P401).

The AO checking portion 151-4 searches the device definition informationbased on the search parameters that have been set up in the SearchParameters Setup window, and displays, in the Device List Display field503, the devices 10 that match the search parameters.

Following this, the operator selects entries for devices 10 for which toperform the “AO Check” from the device list that is displayed in theDevice List Display field 503, and selects, from the Checkpoint CountSetup menu 501, the number of checkpoints (3 points or 5 points) for the“AO Check” for the selected devices 10 (Process P402). Moreover, theoperator puts a check into the Round Trip checkbox 502 if the “AO Check”is to be performed with a “Round Trip” (Process P403).

Following this, the operator operates, for example, the operating unit19 to send, to the controller 17, an electric current value that is theOutput command for the device 10 (Process P404). For example, if theOutput command is 0%, then the electric current value is set to 4 mA, if50%, then 12 mA, or if 100%, then 20 mA. Note that the electric currentvalue setting for the controller 17 may be performed from the devicemonitoring unit 15.

The controller 17 sends, to the I/O module 11, the electric currentvalue of specified by the operating unit 19. This electric current valueis received by the calculating portion 111 through the interface 110 ofthe I/O module 11. The calculating portion 111 applies the specifiedelectric current value through an analog signal to the device 10 throughthe DAC 113, the separating/superimposing portion 1155, and theinterface 1156. Note that the calculating portion 111 stores, in, forexample, the memory 114, the specified electric current value (thedigital setting value) from the controller 17.

The device 10 (the calculating portion 101) outputs an analog DC signalto the I/O module 11 through the DAC 103 in accordance with thespecified electric current value received from the I/O module 11 throughthe interface 108, the separating/superimposing portion 105, and the ADC102. Note that the calculating portion 101 stores, in the memory 104,for example, the electric current value (the digital setting value)received from the I/O module 11.

On the other hand, the device monitoring unit 15 (the AO checkingportion 151-4) sends, to the TCP/UDP communication route 16, the smartcommunication command (the Read command) for obtaining the electriccurrent value that is stored in the memory 104 of the device 10, or inother words, the electric current value (the digital setting value) thatis applied to the DAC 103.

The Read command is received by the smart communications processingportion 115 of the I/O module 11 through the TCP/UDP communication route16, and the smart communications processing portion 115 (the calculatingportion 1152) applies, to the smart communications modem 1154 the Readcommand that has been received. As a result, the Read command isconverted (modulated) by the smart communications modem 1154 into twodifferent frequency signals corresponding to the digital value, and issuperimposed onto the analog DC signal to the device 10 by theseparating/superimposing portion 1155, to be sent to the device 10.

The two different frequency signals are received by the interface 108 ofthe device 10, are separated from the analog DC signal by theseparating/superimposing portion 105, and are converted into therespective corresponding digital values (that is, the Read command) bythe smart communications modem 107, and are received by the calculatingportion 101.

The calculating portion 101, upon receipt of the Read command throughthe smart communication from the I/O module 11, as described above,applies, to the smart communications modem 107, the electric currentvalue that is applied to the DAC 103, which is the digital setting valuestored in the memory 104. As a result, the electric current value isconverted (modulated) by the smart communications modem 107 into twodifferent frequency signals corresponding to the digital value, and issuperimposed onto the analog DC signal to the I/O module 11 by theseparating/superimposing portion 105, to be sent to the I/O module 11.

The two different frequency signals are received by the smartcommunications processing portion 115 (the interface 1156) of the I/Omodule 11, are separated from the analog DC current by theseparating/superimposing portion 1155, are converted into the respectivecorresponding digital values (that is, the digital setting value for theelectric current value, described above) by the smart communicationsprocessing portion 115, and are received by the calculating portion1152. The calculating portion 1152 sends the received electric currentvalue through the NIC 1151 and the TCP/UDP communication route 16 to thedevice monitoring unit 15. In this way, the device monitoring unit 15obtains the electric current value of the analog DC signal that isoutputted to the I/O module 11 by the device 10, as a digital valueprior to the DA conversion by the DAC 103.

On the other hand, the device monitoring unit 15 (AO checking portion151-4), in cooperation with the link module 15A, obtains, through theI/O module 11 (for example, the calculating portion 1152 of the smartcommunications processing portion 115), the electric current value thatis stored in the memory 114, that is, the electric current value (thedigital setting signal) that was the Output command from the I/O module11 to the device 10, as the electric current value that is the digitalvalue applied by the calculating portion 111 to the DAC 113 (hereinafteralso termed the “I/O module output value”) (Process P406), and thenwaits for a specific time interval (the AI check read interval) (ProcessP407). Note that the digital value applied by the calculating portion111 to the DAC 113 may be provided to the device monitoring unit 15through, for example, sending, from the NIC 1151 to the TCP/UDPcommunication route 16, a digital value obtained through, for example,the calculating portion 1152 communicating with the calculating portion111 (communication between CPUs).

The AO checking portion 151-4 repeats the aforementioned Processes P405through P407 until the values obtained from the device 10 and the I/Omodule 11 are within the AO check error threshold value (Route N inProcess 408).

If the values obtained from the device 10 and the I/O module 11 arewithin the AO check error limit threshold value, then the AO checkingportion 151-4 records the average value.

Following this, the device monitoring unit 15 (the AO checking portion151-4) repeats the aforementioned processes P404 through P408 for thecheckpoint count specified in the Checkpoint Count Setup menu 401 (RouteN in the Process P409).

When the aforementioned repetitions have been completed (Route Y inProcess P409), if the “Round Trip” “AO Check” is specified (Route Y inProcess P410), the AO checking portion 151-4 follows the checkpoints inthe reverse sequence and repeats the processes P404 through P409 until0% is reached (Route N in Process P411). For example, in the case of a3-point round trip, the checks are executed in the sequence of0%→50%→100%→50% 0%.

Once the “Round Trip” checks have been completed (Route Y in ProcessP411), the AO checking portion 151-4 repeats the processes P404 throughP411 until the “AO Check” has been completed for all of the devices 10that are subject to the “AO Check” (Route N in Process P412).

When the “AO Check” has been completed for all of the devices 10 (RouteY in Process P412), then the AO checking portion 151-4 compares theoutput specification values from the controller 17 to the device outputvalues and I/O module output values that have been obtained,respectively, from the devices 10 and the I/O modules 11.

If the comparison result is that each of the output values and I/Omodule input values are within a specific tolerance error ranges (the AOcheck error threshold values (%)) for the respective output commandvalues from the respective controllers 17, then the AO checking portion151-4 evaluates the “AO Check” result as “OK,” but if not within thetolerance error range, then the evaluation will be “NG.”

Moreover, when the Report button 203 is clicked, the AO checking portion151-4 produces a report file of the “AO Check” results in a specificformat, such as CSV (Process P413). By way of illustration, the reportfile may include the AO check settings (point count, round trip, etc.),the output demand values to the devices 10 from the controllers 17, thedevice output values, the device input values (the I/O module outputvalues), the evaluation results, the dates and times, and the like.

As described above, the device monitoring unit 15 is able to check,through the monitoring system, for the proper operation of the device 10in accordance with the output value specified through the controllingsystem, through the functions of the AO checking portion 101-4.Consequently, it is possible for the operators to perform the factorystartup operations smoothly. The result is a major contribution to areduction in the operating load on the operators, a shortening of leadtimes (and, by extension, a reduction in power consumption, and thelike), and to ensuring safety of the factory, plant, or the like.

Additionally, the device monitoring unit 15 is able to obtain, throughthe monitoring system, the electric current value (digital settingvalue) that is applied by the I/O module 11 to the device 10, thusmaking it possible to check the state (Normal/Fault) of the controlcommunication through the controller 17 and the digital communicationroute 18 that structure the controlling system. Moreover, it also makesit possible to perform checks regarding, for example, whether or not theI/O module 11 is operating properly in response to the controlcommunication.

Moreover, the device monitoring unit 15 can compare a device outputvalue and an I/O module output value, and thus can check for the properoperation of the DAC 103 of the device 10 and/or the DAC 113 of the I/Omodule 11. Moreover, it is possible to check the status (Normal/Fault)of the communication through the digital communication route 16 thatcomprises the monitoring system and the status (Normal/Fault) of thecommunication through the analog communication route between the device10 and the I/O module 11.

(1-4-5) Progress Check

The “Progress Check” is a function that is able to control and check,for each individual device 10, the state of progress of each of theprocesses (operations) described above, namely the “Device ExistenceCheck,” the “Commissioning,” the “AI Check,” and the “AO Check.”

The functions of the “Progress Check” (the progress checking portion151-5, shown in FIG. 4), as shown in FIG. 17, for example, are placed inan executable state through the selection of the Progress tab 205 in theLoop Checking Tool window. In this state wherein the Progress tab 225 isdisplayed, the buttons and fields indicated by the same codes as in FIG.7 provide the corresponding functions to the “Progress Check.”

For example, the information for the route to the device 10 can be usedin the search parameters (search key) for device searching by the Searchbutton 201 in the state that the Progress Check tab 225 is displayed.The search key may be held in the device monitoring unit 15 as long asthe loop check tool has not finished.

When the Report button 203 is clicked, the progress checking portion151-5 creates a report file in a specific format, such as CSV, of theoperation progress status (for example, dates and times, etc.) for the“Device Existence Check,” the “Commissioning,” the “AI Check,” and “AOCheck,” individually.

The Progress Rate Display field 205, Clear button 206, and Executebutton 208 may be set so as to not be used in the “Progress Check.”

A Device List Display field 601 may be provided in the Progress tab 225.By way of illustration, for each device 10 the operation progress status(dates and times, and the like) may be displayed for the “deviceexistence check,” “Commissioning,” “AI Check,” and “AO Check,”separately, in the Device List Display field 601.

In the field 601, those device entries wherein the results of thevarious texts were “NG” may be displayed with a background color that isdifferent from the colors of the other entries (for example, red) toprovide a highlighted display, so as to be easily identified by theoperators. Note that those items which have not been completed may beleft blank.

In this way, in the device monitoring unit 15 it is easy to checkwhether or not the “Device Existence Check”, the “Commissioning,” andthe AI/AO checks have each been completed in the loop check operationprocesses, in the Device List Display field 601 in the Progress tab 225.Consequently, it is possible to prevent omissions of checks, redundantchecks, and the like, thereby greatly contributing to efficiency ofoperating processes, reduced operating labor for the operators,assurance of system safety, and so forth.

(2) Other

Note that while, in the example set forth above, the explanation was fora process controlling system 1 wherein there was a mixture of smartcommunication-compatible field devices 10 and I/O unit 11 with fielddevices 12 and I/O units 13 that were not smartcommunication-compatible, it may also be applied when all of the fielddevices and I/O units provided in the system 1 are smartcommunication-compatible.

The invention claimed is:
 1. A field device controlling systemcomprising: a field device; a controller connected to the field deviceto communicate through a first communication route; and a devicemonitoring unit connected to the field device to communicate through asecond communication route distinct from the first communication route,the device monitoring unit including a checking unit checking a statusof the field device and a status of communication through at least oneof the first and the second communication route, the checking unitincluding a checking tool executing, through the second communicationroute, a check regarding a connection status, device information, and ananalog input of a field device, and executing, through the secondcommunication route, a check regarding an analog output of the fielddevice, controlled by the controller through the first communicationroute.
 2. The field device controlling system as set forth in claim 1,wherein: the checking tool controls the statuses of progress of eachindividual check, for the respective checks, separately for each fielddevice.
 3. The field device controlling system as set forth in claim 1,wherein: the first communication route includes an analog communicationroute transmitting analog signals between field devices; and the secondcommunication route includes a digital communication route sendingdigital signals superimposed, as frequency signals, on the analogsignals in the analog communication route.